Polaris RZR 800
WORKSHOP MANUAL & OWNER´S MANUAL
POLARIS RZR 800 (2008-2013) - REPAIR, SERVICE, WORKSHOP MANUAL - OWNERS - English Workshop Manual, Wiring Diagram and Owners Manual to Polaris RZR 800. CONTENTS: WORKSHOP MANUAL: GENERAL INFORMATION - VEHICLE IDENTIFICATION - Model number designation - Engine designation number - Vehicle identification number (vin) designation - Vehicle and engine serial number locations - VEHICLE INFORMATION - Publication numbers - Replacement keys - SPECIAL TOOLS - GENERAL SPECIFICATIONS - Model: 2013 ranger rzr - Model: 2013 ranger rzr eps - Model: 2013 ranger rzr / eps - Model: 2013 ranger rzr s - Model: 2013 ranger rzr s int’l - Model: 2013 ranger rzr s / int’l - Model: 2013 ranger rzr 4 - Model: 2013 ranger rzr 4 eps - Model: 2013 ranger rzr 4 / eps - MISC. SPECIFICATIONS AND CHARTS - Conversion table - Standard bolt torque specification - Metric bolt torque specification - Sae tap / drill sizes - Metric tap / drill sizes - Decimal equivalents MAINTENANCE - PERIODIC MAINTENANCE CHART - Periodic maintenance overview - Break-in period - Maintenance chart key - Pre-ride - 50 hour maintenance interval - 100 - 300 hour maintenance interval - Maintenance quick reference - Maintenance quick reference, continued..... - Grease lubrication points - LUBRICANTS / SERVICE PRODUCTS - Polaris lubricants, maintenance and service products - GENERAL VEHICLE INSPECTION AND MAINTENANCE - Pre-ride / daily inspection - Frame, nuts, bolts, and fasteners - Shift cable inspection / adjustment - FUEL SYSTEM AND AIR INTAKE - Fuel system - Fuel line - Fuel pump / fuel filters - Vent lines - Throttle pedal inspection - Throttle freeplay adjustment - Air filter service - ENGINE - Engine oil level - Engine oil and filter service - Engine breather hose inspection - Engine and transmission mounts - Compression and leakdown test - Exhaust - spark arrestor - TRANSMISSION AND GEARCASES - Transmission / gearcase specification chart - Transmission lubrication - Front gearcase lubrication - Rear gearcase lubrication - COOLING SYSTEM - Cooling system overview - Coolant level inspection - Coolant strength / type - Cooling system pressure test - Cooling system hoses - Radiator - Coolant drain - FINAL DRIVE / WHEEL AND TIRE - Wheel and hub torque table - Wheel removal - Wheel installation - Tire inspection - Tire pressure - Drive shaft boot inspection - ELECTRICAL AND IGNITION SYSTEM - Battery maintenance - Battery removal - Battery installation - Battery off season storage - Battery charging (maintenance free) - Spark plug service - Engine to frame ground - STEERING - Steering inspection - Steering wheel freeplay - Tie rod end / wheel hub inspection - Wheel toe alignment inspection - Wheel toe adjustment - SUSPENSION (STANDARD) - Spring preload adjustment - SUSPENSION (FOX™) - Spring preload adjustment - Shock compression adjustment - BRAKE SYSTEM - Brake fluid inspection - Brake pad / disc inspection - Brake hose and fitting inspection ENGINE / COOLING - ENGINE SPECIFICATIONS - Crankcase exploded views - Oil pump / gears / engine cover exploded view - Stator cover / starter / water pump / lubrication system exploded view - Cylinder / cylinder head / piston exploded view - Engine efi sensors / valve cover / general components exploded view - Engine torque specifications - 800 efi engine service specifications - Special tools - ENGINE COOLING SYSTEM - Cooling system specifications - Cooling system pressure test - Pressure cap test - Cooling system exploded view - Radiator removal - Cooling system bleeding procedure - GENERAL ENGINE SERVICE - Engine lubrication specifications - Oil pressure test - Accessible engine components - Oil flow chart - Engine removal - Engine / transmission separation - ENGINE DISASSEMBLY AND INSPECTION - Cylinder head assembly exploded view - Rocker arms - Push rods - Cylinder head removal - Cylinder head inspection - Cylinder head warp - Valve seal / spring service (on engine) - Cylinder head disassembly - Valve inspection - Combustion chamber - Valve seat reconditioning - Cylinder head reassembly - Valve sealing test - Cylinder removal - Valve lifter removal / inspection - Piston removal - Cylinder inspection - Cylinder hone selection and honing procedure - Honing to deglaze - Cleaning the cylinder after honing - Piston-to-cylinder clearance - Piston / rod inspection - Piston ring installed gap - Starter drive bendix removal / inspection - Flywheel / stator removal / inspection - Engine crankcase disassembly / inspection - Camshaft inspection - ENGINE REASSEMBLY - Crankcase reassembly - Flywheel / stator installation - Cylinder head reassembly - Oil pump priming - ENGINE INSTALLATION - Engine assembly and installation - Engine break-in period - TROUBLESHOOTING - Engine - Cooling system ELECTRONIC FUEL INJECTION - GENERAL INFORMATION - Special tools - Service notes - Efi system exploded view - Efi system component locations - FUEL TANK - Exploded view - Fuel line removal / installation - ELECTRONIC FUEL INJECTION - Principal components - Efi operation overview - Initial priming / starting procedure - ELECTRONIC CONTROL UNIT (ECU) - Operation overview - Ecu service - Ecu replacement - TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP) - Operation overview - T-map sensor test - T-map sensor replacement - CRANKSHAFT POSITION SENSOR (CPS) - Operation overview - Cps test - Cps replacement - FUEL INJECTORS - Operation overview - Fuel injector service - Fuel injector test - Fuel injector replacement - FUEL PUMP - Operation overview - Fuel sender test - Fuel pump test - Fuel pump replacement - Fuel tank removal (rzr / rzr s) - Fuel tank removal (rzr 4) - Fuel tank installation - IDLE AIR CONTROL (IAC) - Operation overview - Iac test - Iac replacement - THROTTLE POSITION SENSOR (TPS) - Operation overview - Tps resistance tests - Tps tester / regulator - Tps replacement - CAMSHAFT PHASE SENSOR - Operation overview - Cam phase sensor test - Cam phase sensor replacement - ENGINE COOLANT TEMPERATURE SENSOR (ECT) - Operation overview - Ect sensor test - Ect sensor replacement - IGNITION COIL - Operation overview - Ignition coil / ht lead replacement - Ignition coil tests - EFI DIAGNOSTICS - Instrument cluster trouble code display - Efi troubleshooting - DIGITAL WRENCH™ OPERATION - Digital wrench™ diagnostic software overview - Special tools (also refer to page 4.2) - Diagnostic software version - Ecu replacement - Guided diagnostic available - Digital wrench™ communication errors - Digital wrench™ - diagnostic connector - Digital wrench™ serial number location - Digital wrench™ version and update id - Digital wrench™ updates - Digital wrench™ feature map - Engine controller reprogramming (reflash) BODY / STEERING / SUSPENSION - TORQUE SPECIFICATIONS - SPECIAL TOOLS - Multi-function pliers - CAB FRAME (RZR / RZR S) - Assembly / removal - CAB FRAME (RZR 4) - Assembly / removal - BODY EXPLODED VIEWS - Side safety nets - Dash instruments / controls / glovebox - Hood / front body work - Rear bumper - Seat assembly - Seat belts / mounting (rzr / rzr s) - Seat belts / mounting (rzr 4) - Floor / rocker panels (rzr / rzr s) - Floor / rocker panels (rzr 4) - Rear cargo box / fenders (rzr / rzr s) - Rear cargo box / fenders (rzr 4) - Chassis / main frame (rzr / rzr s) - Chassis / main frame (rzr 4) - BODY COMPONENT REMOVAL - Seats - Rear service panel (rzr / rzr s) - Rear console cover (rzr 4) - Front bumper - Rear bumper - Hood and front body work - Rear fender, flair and tie down removal - Cargo box assembly removal - Rocker panels, console and floor - STEERING ASSEMBLY - Exploded view (non-eps models) - Steering wheel removal (non-eps models) - Steering shaft removal (non-eps models) - Steering shaft bearing replacement - ELECTRONIC POWER STEERING ASSEMBLY - Exploded view (eps models) - Upper steering shaft removal (eps models) - Steering wheel removal (eps models) - Power steering unit removal - Lower steering shaft removal (eps models) - Lower steering shaft installation (eps models) - Power steering unit installation - Upper steering shaft installation (eps models) - FRONT A-ARMS - Removal / replacement - Exploded view (rzr) - Exploded view (rzr s / rzr 4) - BALL JOINT SERVICE - Service preparation - Ball joint removal - Ball joint installation - FRONT STABILIZER BAR (RZR / RZR S INT’L) - Stabilizer bar linkage removal - Stabilizer bar removal - Exploded view - REAR A-ARMS - Removal - Installation - Exploded view (rzr) - Exploded view (rzr s / rzr 4) - REAR STABILIZER BAR (RZR) - Removal / installation - REAR STABILIZER BAR (RZR S / RZR 4) - Removal / installation - DECAL REPLACEMENT - SHOCKS / SPRINGS / FASTENERS - Exploded view (rzr / rzr s) - Exploded view (rzr s / rzr s int’l) - Exploded view (rzr 4) - Shock removal / installation - Shock replacement - FOX™ PODIUM PIGGYBACK SHOCK SERVICE - Fox™ 1.5 podium ‘piggyback’ shock (rzr s) - Fox™ 1.5 podium ‘piggyback - general service information - Front shock service (rzr s) - Rear shock service (rzr s) - Fox™ 2.0 podium ‘piggyback’ shock (rzr 4 l.e. Models) - Fox™ 2.0 podium ‘piggyback - general service information - Front shock service (rzr 4 l.e models) - Rear shock service (rzr 4 l.e. Models) - Fox™ podium ‘piggyback’ rebuild information - Fox™ podium ‘piggyback’ special tools - Fox™ podium ‘piggyback’ disassembly - Fox™ podium ‘piggyback’ body and reservoir service - Fox™ podium ‘piggyback’ component rebuild - Fox™ podium ‘piggyback’ assembly - FOX™ PODIUM TOP FILL SHOCK SERVICE - Fox™ 2.0 podium top fill shock (rzr 4 base models) - Fox™ 2.0 podium top fill - general service information - Front shock service (rzr 4 base models) - Rear shock service (rzr 4 base models) - Fox™ 2.0 podium top fill disassembly - Fox™ 2.0 podium top fill reassembly CLUTCHING - SPECIAL TOOLS AND SUPPLIES - TORQUE SPECIFICATIONS - Pvt system fastener torques - HIGH ALTITUDE CLUTCH CHARTS - Ranger rzr / rzr s / rzr 4 - Ranger rzr eps (ebs model) - PVT SYSTEM OVERVIEW - General operation - Drive clutch operation - Driven clutch operation - Pvt break-in (drive belt / clutches) - Maintenance / inspection - Overheating / diagnosis - PVT SYSTEM SERVICE - Pvt covers and ducting components - Pvt disassembly - Pvt assembly - Clutch offset procedure - DRIVE BELT (NON-EBS) - Belt removal - Belt inspection - Belt installation - DRIVE BELT (EBS) - Belt removal - Belt inspection - Belt installation - DRIVE CLUTCH SERVICE - Exploded view - Shift weights - Clutch disassembly - Bearing inspection - Drive clutch spring inspection - Shift weight inspection - Button to tower clearance inspection - Spider removal - Roller, pin, and thrust washer inspection - Clutch inspection - Moveable sheave bushing inspection - Bushing service - Clutch assembly - DRIVEN CLUTCH SERVICE (NON-EBS) - Exploded view - Clutch disassembly / inspection - Clutch assembly - DRIVEN CLUTCH SERVICE (EBS) - Clutch disassembly - Bushing service - Clutch assembly - Exploded view - TROUBLESHOOTING FINAL DRIVE - SPECIAL TOOLS - TORQUE SPECIFICATIONS - Wheel and hub torque table - FRONT BEARING CARRIER - Bearing carrier inspection / removal - Bearing replacement - Bearing carrier installation - FRONT DRIVE SHAFT - Drive shaft removal - Drive shaft / cv joint handling tips - Outer cv joint / boot replacement - Inner plunging joint / boot replacement - Drive shaft installation - PROPSHAFT SERVICE - Removal / installation (rzr / rzr s) - Removal / installation (rzr 4) - Support bearing replacement (rzr 4) - PROPSHAFT U-JOINT SERVICE - Disassembly - Assembly - FRONT GEARCASE / CENTRALIZED HILLIARD - Centralized hilliard exploded view - All wheel drive operation - Awd diagnosis - Gearcase removal - Gearcase disassembly / inspection - Gearcase assembly - Gearcase installation - REAR BEARING CARRIER - Bearing carrier inspection / removal - Bearing replacement - Bearing carrier bushing replacement - Bearing carrier installation - REAR DRIVE SHAFT - Drive shaft removal - Outer cv joint / boot replacement - Inner plunging joint / boot replacement - Drive shaft exploded view - Drive shaft installation - REAR GEARCASE - Gearcase removal - Gearcase disassembly - Gearcase assembly - Gearcase installation - Gearcase exploded view - REAR GEARCASE (RZR S INT’L) - General operation - Gearcase removal - Gearcase disassembly - Differential disassembly - Differential assembly - Gearcase assembly - Gearcase installation - Gearcase exploded view - WHEEL HUBS - Front hub exploded view - Rear hub exploded view TRANSMISSION - TORQUE VALUES / SPECIFICATIONS - SHIFT LEVER - Removal - Installation - Shift cable inspection / adjustment - TRANSMISSION SERVICE - Transmission removal / service notes - Transfer case disassembly - Transfer case reassembly - Transmission shift housing disassembly - Transmission shift housing reassembly - TROUBLESHOOTING - Troubleshooting checklist - TRANSMISSION EXPLODED VIEW - Shift housing / transfer case exploded view BRAKES - GENERAL SPECIFICATIONS - TORQUE SPECIFICATIONS - SPECIAL TOOLS - BRAKE SYSTEM SERVICE NOTES - BRAKE NOISE TROUBLESHOOTING - HYDRAULIC BRAKE SYSTEM OPERATION - BRAKE SYSTEM EXPLODED VIEW - Rzr / rzr s / rzr s int’l - Rzr 4 - MASTER CYLINDER - Removal - Installation - BRAKE PEDAL LEVER - Pedal removal - Pedal installation - BRAKE BLEEDING / FLUID CHANGE - FRONT BRAKE PADS - Pad removal - Pad inspection - Pad assembly / installation - Brake burnishing procedure - FRONT CALIPER SERVICE - Caliper exploded view (rzr / rzr s / rzr s int’l) - Caliper exploded view (rzr 4) - Caliper removal - Caliper disassembly - Caliper inspection - Caliper assembly - Caliper installation - FRONT BRAKE DISC - Disc runout - Disc inspection - Disc replacement - REAR BRAKE PADS - Pad removal - Pad inspection - Pad assembly / installation - Brake burnishing procedure - REAR CALIPER SERVICE - Caliper exploded view - Caliper removal - Caliper disassembly - Caliper inspection - Caliper assembly - Caliper installation - REAR BRAKE DISC - Disc inspection - Disc replacement - TROUBLESHOOTING - Brakes squeal / poor brake performance - Pedal vibration - Caliper overheats (brakes drag) - Brakes lock CHAPTER 10 - ELECTRICAL - GENERAL INFORMATION - Special tools - Electrical service notes - Under-dash components - SWITCHES / CONTROLS - Brake light switch - Headlamp switch - Ignition key switch - Ignition key switch (int’l) - Awd / 2wd switch - Awd / 2wd / turf switch (int’l) - Turn signal switch (int’l) - Hazard switch (int’l) - Transmission (gear position) switch - Throttle release switch (trs) - VEHICLE SPEED SENSOR - Speed sensor location - Speed sensor testing - REAR DIFF SOLENOID (INT’L) - Differential solenoid overview - Differential solenoid circuit operation - ALL WHEEL DRIVE COIL - Operation overview - Diagnosing system failures - Instrument Cluster - Overview - Rider information display - Information display area - Diagnostic mode - Instrument cluster pinouts - Instrument cluster removal - Instrument cluster installation - HEAD LIGHTS (INCANDESCENT) - Headlight adjustment - Headlamp bulb replacement - Headlamp housing removal - Headlamp housing installation - HEAD LIGHTS (led) - Headlight adjustment - Headlamp replacement - Headlamp installation - TAIL / BRAKE LIGHTS - Bulb replacement - COOLING SYSTEM - Cooling system break-out diagram - Fan control circuit operation / testing - Fan control circuit bypass test - Coolant temperature sensor - EFI DIAGNOSTICS - Efi component testing - FUEL SENDER - Testing - FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKER - Overview / operation - Fuse box detail - Relay operation - CHARGING SYSTEM - Current draw - key off - Charging system “break even” test - Charging system alternator tests - Regulator / rectifier - Charging system testing flow chart - BATTERY SERVICE - Battery specifications - General battery information - Battery removal / installation - Battery off season storage - Battery testinG - Ocv - open circuit voltage test - Load test - Battery conductance analyzer - Charging procedure - STARTING SYSTEM - Troubleshooting - Voltage drop test - Starter motor removal - Starter installation - Starter drive bendix - Starter solenoid bench test - Starter solenoid operation - STARTING SYSTEM TESTING FLOW CHART - Condition: starter fails to turn over the engine. - ELECTRONIC POWER STEERING (EPS) - Eps operation - Proper eps system diagnosing - Eps system breakout - Eps troubleshooting (power steering non-functional with mil on) - Eps troubleshooting (power steering non-functional with mil off) - Eps troubleshooting (using digital wrench™) 9924125_WIRE_DIAGRAMS_11X17 9924125_Wire_Diagram_RZR_11x17 9924125_Wire_Diagram_RZR_11x17_2 9924125_Wire_Diagram_RZR_EPS_11x17 9924125_Wire_Diagram_RZR_EPS_11x17_2 9924125_Wire_Diagram_RZRS_11x17 9924125_Wire_Diagram_RZRS_11x17_2 9924125_Wire_Diagram_RZRS_INTL_11x17 9924125_Wire_Diagram_RZRS_INTL_11x17_2 9924125_Wire_Diagram_RZR4_11x17 9924125_Wire_Diagram_RZR4_11x17_2 9924125_Wire_Diagram_RZR4_EPS_11x17 9924125_Wire_Diagram_RZR4_EPS_11x17_2 9924125_Wire_Diagram_RZR_RZRS_RZR4_CargoBox_11x17 9924125_Wire_Diagram_RZRS_INTL_CargoBox_11x17 OWNER’S MANUAL: FEATURES AND CONTROLS - Component Locations - Rear Service Panel - Steering Wheel - Passenger Hand Hold - Hood - Fuel Cap - Cab Nets - Seat Belts - Switches - Gear Selector - Brake Pedal - Throttle Pedal - All Wheel Drive (AWD) System - Instrument Cluster OPERATION - Vehicle Break-in Period - Pre-Ride Inspection - Safe Operation Practices - Starting the Engine - Stopping the Engine - Braking - Parking the Vehicle - Know Your Riding Area/Tread Lightly - Trail Etiquette - New Operator Driving Procedures - Driving with Passengers - Driving on Slippery Surfaces - Driving Uphill - Driving on a Sidehill (Sidehilling) - Driving Downhill - Driving Through Water - Driving Over Obstacles - Driving in Reverse - Parking on an Incline - Hauling Cargo EMISSION CONTROL SYSTEMS MAINTENANCE - Periodic Maintenance Chart - Lubrication Recommendations - Engine Oil - Gearcases - Spark Plugs - Fuses - Cooling System - POLARIS Variable Transmission (PVT) System - Filter Systems - Spark Arrestor - Throttle System - Brakes - Suspension Settings - Tires - Lights - Battery - Cleaning and Storage SPECIFICATIONS POLARIS PRODUCTS TROUBLESHOOTING DECLARATION OF CONFORMITY WARRANTY MAINTENANCE LOG INDEX
Polaris RZR 800 (2008-2013) - Workshop Manual - Wiring Diagram - Owners Manual
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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